Description:FIELD OF INVENTION
[001] The present invention relates to a field of battery pack assembly. Particularly, the present invention relates to a system and method of flipping the battery pack for proper assembly. More particularly, the present invention relates to a specialized system designed to efficiently handle various battery pack types and form factors, thereby utilizing energy efficient method to reduce human fatigue.
BACKGROUND OF THE INVENTION
[002] Traditional methods of handling battery packs during assembly often result in misalignment and inconsistent positioning, leading to defects and reduced efficiency. Also, manual handling and positioning of battery packs are time-consuming and labor-intensive, slowing down the production line and increasing costs. Further, handling battery packs manually poses safety risks, including potential damage to the battery cells and injury to workers due to improper handling. Different battery pack designs and sizes require various handling techniques, making it challenging to standardize the assembly process. Repeated manual handling of battery packs can lead to ergonomic issues for workers, such as strain and fatigue where the battery pack weight is around or above 600 kg.
[003] There are several patent and non-patent documents that disclose battery pack flipping. One of the existing solutions in jigs and fixtures for battery packs include various designs that facilitate the positioning, clamping, and rotation of battery cells to ensure accurate assembly. One notable prior art is the rotating jig for battery cells, which allows for the sequential processing of battery cells of various sizes. This jig includes a main body with a hexahedral structure, a rotating rod, and a support member to hold the battery cell in place during rotation and welding. Another literature and publications include “Jig and Fixture Design Manual” by Erik Karl Henriksen that discloses comprehensive coverage of the fundamental principles of jig and fixture design, including locating, clamping, and the mechanics of cutting tool operations. Further, the principles outlined in this manual are directly applicable to the design of a 180-degree rotating fixture for battery packs, ensuring precise positioning and handling during assembly. Another literature named “Mechanical Design and Packaging of Battery Packs for Electric Vehicles” by Shashank Arora and Ajay Kapoor discloses the mechanical design elements and packaging solutions for battery packs, focusing on safety and reliability. The insights into mechanical design and packaging are crucial for developing a robust and efficient rotating fixture for battery packs. Yet another literature “Design of Jigs, Fixtures and Press Tools” discloses various aspects of jig and fixture design, including illustrations and detailed explanations of different types of fixtures. The detailed design principles and examples provided in the literature guides the development of a 180-degree rotating fixture for battery packs.
[004] One Chinese patent application CN110386545A titled “A kind of battery modules stone tongs” discloses battery modules stone tongs in battery modules lifting field, including a hanging component, a bottom plate, a guiding mechanism, a clamp system, two handles and two index pin. The hanging component, handle and index pin are set to the upper end of bottom plate. The guiding mechanism is set to the lower end of bottom plate. The clamp system is set to the upper end and lower end of bottom plate.
[005] The prior arts lack in precise and consistent positioning of battery pack, better speed of assembly and maintenance tasks, secure and stable platform for flipping and positioning battery packs and accommodating battery packs of various shapes and sizes.
[006] In order to overcome the challenges associated with the state of the arts, there is a need to develop a device for flipping battery packs that can overcome the aforesaid limitations in a more efficient manner.

OBJECTIVE OF THE INVENTION
[007] The primary objective of the present invention is to provide a system for flipping of a battery pack.
[008] Another objective of the present invention is to reduce errors while flipping the battery pack.
[009] Another objective of the present invention is to improve the overall quality of the assembly process.
[0010] Yet another objective of the present invention is to enhance productivity by speeding up assembly and maintenance tasks.
[0011] Another objective of the present invention is to reduce labor costs by automating the flipping process of the battery pack.
[0012] Yet another objective of the present invention is to minimize risk of damage and ensure a safer working environment.
[0013] Another objective of the present invention is to provide a versatile solution that is easily adapted to different assembly requirements.
[0014] Another objective of the present invention is to reduce ergonomic issues for workers, such as strain and fatigue.
[0015] Other objectives and advantages of the present invention will become apparent from the following description taken in connection with the accompanying drawings, wherein, by way of illustration and example, the aspects of the present invention are disclosed.

BRIEF DESCRIPTION OF DRAWINGS
[0016] The present invention will be better understood after reading the following detailed description of the presently preferred aspects thereof with reference to the appended drawings, in which the features, other aspects, and advantages of certain exemplary embodiments of the invention will be more apparent from the accompanying drawing in which:
[0017] Figure 1 illustrates a perspective view of a system of a battery pack flipping;
[0018] Figure 2 illustrates a side view of the system;
[0019] Figure 3 illustrates a top view of a housing structure;
[0020] Figure 4 illustrates a shaft having a plurality of plummer blocks and a plurality of gear;
[0021] Figure 5 illustrates side view of a plurality of plates of the housing structure to be connected on the plummer blocks;
[0022] Figure 6 illustrates a side view of a motor mounted on the housing structure;
[0023] Figure 7 illustrates joining of ends of a plurality of belts using D shackle;
[0024] Figure 8 illustrates placement of the belts under the battery pack;
[0025] Figure 9 illustrates the battery pack hanging on the belts;
[0026] Figure 10 illustrates a motor running to rotate the battery pack to 90 degrees;
[0027] Figure 11 illustrates the motor controlling speed of the rotating shaft;
[0028] Figure 12 illustrates the battery pack rotated 90 degrees;
[0029] Figure 13 illustrates the battery pack is further rotated remaining 90 degree making sure a table is brought back under the battery pack;
[0030] Figure 14 illustrates the battery pack rotated 180 degrees and the table is placed under the battery pack;
[0031] Figure 15 illustrates the battery pack lowered & rested on the rest pad;
[0032] Figure 16 illustrates the D shackle & the belts are removed to move the battery pack; and
[0033] Figure 17 illustrates the table for transporting the battery pack to next station.

SUMMARY OF THE INVENTION
[0034] The present invention relates to a system for flipping a battery pack. The system of flipping battery pack comprises of: a housing structure, a rotating mechanism and a table. Further, the housing structure comprises of a plurality of tubes coupled to form the housing structure, a hook affixed through a fastening screw on the upper end of the housing structure and a plurality of plates attached on the lower end of the housing structure. Furthermore, the rotating mechanism comprises of: a shaft, having a plurality of plummer blocks and a plurality of gears, coupled with the shaft, a plurality of belts movably attached to the gears such that the belts are placed to align with the center of gravity of a battery pack for providing balanced handling, a D-shackle attached to the belts for joining both ends of the belts, a motor mounted on one end of the housing structure with a pair of fasteners, comprises of a controller for providing necessary rotational force to the battery pack while suspended in the air, a pulley attached on one end of the shaft and a V-belt attached to the pulley at one end and to the motor at another end. The table comprises of a rest pad and an at least three wheels.
[0035] The present invention also relates to a method for flipping a battery pack. The method for flipping the battery pack, comprises steps of: joining a battery flipping structure plates with a plurality of plummer blocks of a shaft, placing a plurality of belts on the shaft having a plurality of gears, mounting a motor having a controller for controlling the speed of the motor for providing necessary rotational force to rotate the battery pack to be rotated while suspended in the air, on the battery flipping structure, placing pulley with a belt on the motor, hooking an overhead hanging crane with a hook of the battery flipping structure, placing the belts under the battery pack and joining the belts using a D-shackle such that the belts are placed on the center of gravity of the battery pack ensuring balanced handling, placing the battery pack on a table by using the hanging crane, raising the battery flipping structure along with battery pack above the table at a certain height such that the table is removed, raising the battery pack slowly from one side by rotating the shaft on the motor in the clockwise direction such that the battery pack reaches 90 degrees, controlling the speed of the motor by the controller, putting the table under the battery pack upon the battery pack rotated 90 degree, flipping the battery pack using the motor such that the battery pack reaches 180 degree, lowering the battery pack on the table to make the battery pack rest on a rest pad of the table, making sure the belts are loose and removing the D shackle for removing the belts and transporting the battery pack to required station for assembly of the battery pack.

DETAILED DESCRIPTION OF INVENTION
[0036] The following detailed description and embodiments set forth herein below are merely exemplary out of the wide variety and arrangement of instructions which can be employed with the present invention. The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. All the features disclosed in this specification may be replaced by similar other or alternative features performing similar or same or equivalent purposes. Thus, unless expressly stated otherwise, they all are within the scope of the present invention.
[0037] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
[0038] The terms and words used in the following description and claims are not limited to the bibliographical meanings but are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention.
[0039] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.
[0040] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps, or components but does not preclude the presence or addition of one or more other features, steps, components, or groups thereof.
[0041] Accordingly, the present invention relates to a field of battery pack assembly. Particularly, the present invention relates to a system and method of flipping the battery pack for proper assembly. More particularly, the present invention relates to a specialized system designed to efficiently handle various battery pack types and form factors, thereby utilizing energy efficient method to reduce human fatigue.
[0042] The disclosure relates to a system (100) for flipping a battery pack, including a housing structure (102), a rotating mechanism (110) and a table (132). The housing structure (102) further incorporates a plurality of tubes (104), a hook (106) and a plurality of plates (108). The rotating mechanism (110) further includes a shaft (112), a plurality of belts (118) movably, a D-shackle (122), a motor (124), a pulley (128) and a V-belt. Additionally, the table (132) comprises of a rest pad (134) and an at least three wheels (136).
[0043] Referring to Figures 1-17, the system (100) for flipping the battery pack (120) is depicted in various operational engagements. Figure 1 illustrates a perspective view of the system (100) of flipping battery pack. The system (100) includes a specialized tool designed to efficiently handle various battery pack (120) types and form factors. The disclosure supports battery pack (120) casings made from diverse materials and utilizes energy-efficient methods to reduce human fatigue.
[0044] Figure 2 focuses on a side view of the battery flipping device. The device is able to flip the battery packs weighing around or above 600kg. Further, the battery pack (120) may include, but not limited to, lithium-ion, sodium-ion, nickel-cadmium battery pack and the like.
[0045] In figure 3, the housing structure (102) is shown, including the tubes (104) coupled to form the housing structure (102), the hook (106) affixed through a fastening screw on the upper end of the housing structure (102) and the plates (108) attached on the lower end of the housing structure (102). Further, the housing structure (102) provides a secure and stable platform for flipping and positioning the battery packs, minimizing the risk of damage and ensuring a safer working environment. The tubes (104) used for making the housing structure (102) for making the housing structure (102) stronger.
[0046] Further, the hook (106) affixed on the upper end of the housing structure (102) is provided to be hanged on an overhead crane so that the housing structure (102) is movable to any place as per the requirement of the user. Furthermore, the plates (108) are attached on the lower end of the housing structure (102) to connect the housing structure (102) with the rotating mechanism. The plates (108) may be attached through welding, fastening screws and the like.
[0047] In an exemplary embodiment, the tubes (104) are made with a material including, but not limited to, mild steel sheet, stainless steel, carbon steel, alloy steel. Further, the tubes (104) may be coupled through the process including, but not limited to, welding, fastening screws and the like.
[0048] As illustrated in combination of figures 4 to 6, the rotating mechanism (110) includes the shaft (112) having a plurality of plummer blocks (114) and a plurality of gears, coupled with the shaft (112). The plummer blocks (114) and gears (116) may be welded, connected through fastening screws on the shaft (112). In an exemplary embodiment, the shaft (112) is made from the material selected from a group of austenitic, ferritic, martensitic and duplex (austenitic-ferritic) stainless steel. In another exemplary embodiment, the plummer blocks (114) in the present invention are five in number with a diameter of 30mm. In yet another exemplary embodiment, the gears (116) used in the present invention are four in number with a diameter of 30 mm.
[0049] Further, as illustrated in figure 7, the plurality of belts (118) are movably attached to the gears (116) such that the belts (118) are placed to align with the center of gravity of a battery pack (120) for providing balanced handling. Both the ends of the belts (118) are joined by using the D-shackle (122). In an exemplary embodiment, the belts (118) are four in quantity with a length of 5 meters such that the belts (118) withstand at least 1 ton load of the battery pack. The belts (118) are placed on the gears (116) such that to avoid slipping of the battery pack (120) by providing friction between the shaft (112) & the belts (118) at the time of battery pack (120) rotation.
[0050] As illustrated in combination of figures 8 to 10, the motor (124) is mounted on one end of the housing structure (102) with a pair of fasteners. The motor (124) includes a controller (126) for providing necessary rotational force to the battery pack (120) while suspended in the air. The motor (124) is welded on a mount structure for being mounted to the housing structure (102) by using nuts and bolts. In an exemplary embodiment, the motor (124) used is an induction motor of power at least of 10KW. In another exemplary embodiment, the controller (126) of the motor (124) is a teach pendant to control the speed of the motor (124) that rotates the shaft (112) in clockwise direction at maximum 5rpm.
[0051] The pulley (128), as shown in figure 11 and figure 12, is attached on the shaft (112) and the V-belt (130) attached on the pulley (128) at one end and to the motor (124) at another end. The pulley (128) and the V-belt (130) are provided to rotate the shaft (112) in an efficient manner such that the battery pack (120) is flipped properly.
[0052] As illustrated in combination of figures 13 to 17, the table (132) is provided to put the battery pack (120) and move to the desired location to assemble the battery pack (120) on a device. Further, the table (132) is used to transport the battery pack (120) to the housing structure (102). The table (132) provides a stable platform for positioning the battery pack (120) beneath the housing structure (102). The battery pack (120) is initially placed on the table (132) and then moved under the housing structure (102). Upon securing the belts, the table (132) is retracted to allow the battery pack (120) to be lifted and rotated.
[0053] In an embodiment, the present invention also provides a method (200), as shown in combination of figures 3 to 17, for flipping battery pack (120) comprises the following steps:-
i. joining a plurality of plates (108) of a housing structure (102) with a plurality of plummer blocks (114) of a shaft (112);
ii. placing a plurality of belts (118) on the shaft (112) having a plurality of gears (116);
iii. mounting a motor (124) having a controller (126) for controlling the speed of the motor (124) for providing necessary rotational force to rotate the battery pack (120) to be rotated while suspended in the air, on the housing structure (102);
iv. placing pulley (128) with a V- belt (134) on the motor (124);
v. hooking an overhead hanging crane with a hook (106) of the housing structure (102);
vi. placing the belts (118) under the battery pack (120) and joining the belts (118) using a D-shackle (122) such that the belts (118) are placed on the center of gravity of the battery pack (120) ensuring balanced handling;
vii. placing the battery pack (120) on a table (132) by using the hanging crane;
viii. raising the housing structure (102) along with battery pack (120) above the table (132) at a certain height such that the table (132) is removed;
ix. raising the battery pack (120) slowly from one side by rotating the shaft (112) on the motor (124) in the clockwise direction such that the battery pack (120) reaches 90 degrees;
x. controlling the speed of the motor (124) by the controller (126);
xi. putting the table (132) under the battery pack (120) upon rotating the battery pack (120) to 90 degree;
xii. flipping the battery pack (120) using the motor (124) such that the battery pack (120) reaches 180 degree;
xiii. lowering the battery pack (120) on the table (132) to make the battery pack (120) rest on a rest pad (134) of the table (132);
xiv. making sure the belts (118) are loose and removing the D shackle for removing the belts (118); and
xv. transporting the battery pack (120) to required station for assembly of the battery pack (120).
[0054] The advantages of the present invention are enlisted herein:
• The present invention reduces errors while flipping the battery pack.
• The present invention improves the overall quality of the assembly process.
• The present invention enhances productivity by speeding up assembly and maintenance tasks.
• The present invention reduces labor costs by automating the flipping process of the battery pack.
• The present invention minimizes risk of damage and ensure a safer working environment.
• The present invention provides a versatile solution that is easily adapted to different assembly requirements.
• The present invention reduces ergonomic issues for workers, such as strain and fatigue.

[0055] While this invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
, Claims:1. A system (100) for flipping battery pack, comprising:
a) a housing structure (102), comprising:
• a plurality of tubes (104) coupled to form the housing structure (102);
• a hook (106) affixed through a fastening screw on the upper end of the housing structure (102); and
• a plurality of plates (108) attached on the lower end of the housing structure (102);
b) a rotating mechanism (110), comprising:
? a shaft (112), having a plurality of plummer blocks (114) and a plurality of gears (116), coupled with the shaft (112);
? a plurality of belts (118) movably attached to the gears (116) such that the belts (118) are placed to align with the center of gravity of a battery pack (120) for providing balanced handling;
? a D-shackle (122) attached to the belts (118) for joining both ends of the belts (118);
? a motor (124) mounted on one end of the housing structure (102) with a pair of fasteners, comprising a controller (126) for providing necessary rotational force to the battery pack (120) while suspended in the air;
? a pulley (128) attached on one end of the shaft (112); and
? a V-belt (130) attached to the pulley (128) at one end and to the motor (124) at another end; and
c) a table (132) comprising a rest pad (134) and an at least three wheels (136).
2. The system (100) as claimed in claim 1, wherein the tubes (104) are made with a material selected from a group of mild steel sheet, stainless steel, carbon steel and alloy steel.
3. The system (100) as claimed in claim 1, wherein the shaft (112) is made from the material selected from a group of austenitic, ferritic, martensitic and duplex (austenitic-ferritic) stainless steel.
4. The system (100) as claimed in claim 1, wherein the plummer blocks (114) have diameter 30mm.
5. The system (100) as claimed in claim 1, wherein the gears (116) are selected from a group of spur gear, worm gear, helical gear, bevel gear.
6. The system (100) as claimed in claim 5, wherein the gears (116) have diameter 30mm.
7. The system (100) as claimed in claim 1, wherein the controller (126) of the motor (124) is a teach pendant.
8. A method (200) of flipping a battery pack (120) by the system (100) as claimed in claim 1, comprising steps of:
i. joining a plurality of plates (108) of a housing structure (102) with a plurality of plummer blocks (114) of a shaft (112);
ii. placing a plurality of belts (118) on the shaft (112) having a plurality of gears (116);
iii. mounting a motor (124) having a controller (126) for controlling the speed of the motor (124) for providing necessary rotational force to rotate the battery pack (120) to be rotated while suspended in the air, on the housing structure (102);
iv. placing pulley (128) with a V- belt (134) on the motor (124);
v. hooking an overhead hanging crane with a hook (106) of the housing structure (102);
vi. placing the belts (118) under the battery pack (120) and joining the belts (118) using a D-shackle (122) such that the belts (118) are placed on the center of gravity of the battery pack (120) ensuring balanced handling;
vii. placing the battery pack (120) on a table (132) by using the hanging crane;
viii. raising the housing structure (102) along with battery pack (120) above the table (132) at a certain height such that the table (132) is removed;
ix. raising the battery pack (120) slowly from one side by rotating the shaft (112) on the motor (124) in the clockwise direction such that the battery pack (120) reaches 90 degrees;
x. controlling the speed of the motor (124) by the controller (126);
xi. putting the table (132) under the battery pack (120) upon rotating the battery pack (120) to 90 degree;
xii. flipping the battery pack (120) using the motor (124) such that the battery pack (120) reaches 180 degree;
xiii. lowering the battery pack (120) on the table (132) to make the battery pack (120) rest on a rest pad (134) of the table (132);
xiv. making sure the belts (118) are loose and removing the D shackle for removing the belts (118); and
xv. transporting the battery pack (120) to required station for assembly of the battery pack (120).